Reaming tool

ABSTRACT

The present invention provides a reaming tool, comprising a channel body having a tubular wall and comprising a dynamic sleeve and a fluid channel across the center of the channel body. There are two or more tubular, drive chambers stacked one after another, and surrounded by a torsional housing having separate segments allowing fluid flow and jetting impact on each segment, each drive chamber having one or more inlet(s) upstream for fluid entry and one or more discharge holes downstream for fluid discharge. A stabilized housing is coupled around the torsional housing and one end of the stabilized housing rotatably coupled with the dynamic sleeve of the channel body, and another end of the stabilized housing is a reamer head having one or more fluid outlet.

BACKGROUND 1. Field of the Invention

The present invention relates to a tool used to ream holes in earth drilling, so as to enlarge the size and/or to smoothen sides of a previously drilled hole.

2. Description of Related Art

A reaming tool or reamer is a type of rotary drilling tool, usually cylindrical, that is used to clean and/or enlarge the size of a previously drilled hole in a process called reaming. Furthermore, the reaming process also smoothens the interior surface of the borehole for a subsequent use. The application of such a reaming tool extends from metal works, such as in a milling machine or drill press, to earth drilling, such as tunnel boring and oil rigging. Very often, drilled holes do not have smooth surfaces due to irregularities caused during the drilling process. Besides, if the borehole is not used immediately, chemical and physical interactions with the surrounding environment cause more distortion in the hole profile, making the borehole more difficult to be operated later on. Therefore, reaming is performed immediately or some time after drilling a hole, prior to operating it.

Conventional reaming tools were mechanically cumbersome and not versatile in application. The field of the technology has seen various improvements in tools for reaming holes, such as prior art U.S. Pat. No. 9,080,384 B2, which discloses an apparatus for cutting a wellbore includes a motor having a stator and a rotor. The rotor has an output shaft connected to a cutting structure. The stator and rotor are spaced radially outwardly of the axis of rotation of the rotor such that at least one of the stator and the rotor had an access bore extending through the motor to adjacent the cutting structure. A further object can pass therethrough, without obstruction. The further object comprises a further cutting. A flow diverter is disposed in the motor proximate a connection between the motor and a wellbore tubular, and has a first fluid outlet in fluid communication with a power section of the motor, and a second fluid outlet in fluid communication with the access bore. The flow diverter is coupled to the stator such that axial loading created by fluid pressure is substantially transferred to the stator. However, the apparatus is difficult to use, being expensive and difficult to replace, being limited in application, and being slow.

U.S. Patent Application 20180148980 A1 discloses a reaming tool that is easier to use while achieving its functional capabilities, less expensive and more versatile than many of the prior art. including a channel body having a fluid channel disposed therethrough. The channel body includes a dynamic sleeve that allows the channel body to rotatably couple. The channel body includes a static sleeve, a dynamic sleeve, a static mandrel, and a radial bearing. The reaming tool includes a drive chamber fixedly coupled to the channel body and including a fluid conduit system. The fluid conduit system is shaped to impart rotational force on the drive chamber when fluid is forced therethrough. The drive chamber includes a post enclosed by stacked drive discs. The fluid conduit system includes an array of curved conduits. The reaming tool includes a stabilized housing fixedly coupled about the drive chambers. The disadvantage of this reaming tool is that its rotation is not fast enough and its torque not high enough for boreholes having significantly hard surfaces and many obstructing structures or blockages.

The present invention is an improved reaming tool designed to solve the aforementioned problems for being easy to use and replace, being inexpensive and versatile in application, yet being fast with high rotational power.

SUMMARY OF THE PRESENT INVENTION

The present invention features a reaming tool, comprising a channel body having a tubular wall and comprising a dynamic sleeve and a fluid channel across the centre of the channel body. There are two or more tubular, drive chambers stacked one after another, with a first drive chamber having an open end in fluid connection with the fluid channel and another closed end in stacking connection with one or more subsequent drive chamber having two closed ends, wherein outer walls of the drive chambers are surrounded in a fixedly engagement by a torsional housing having separate segments allowing fluid flow in each segment. Each drive chamber has one or more inlet upstream for fluid entry and one or more discharge hole downstream for fluid discharge.

A stabilized housing has an inner wall fixedly coupled around the torsional housing and one end of the stabilized housing rotatably coupled with the dynamic sleeve of the channel body, and another end of the stabilized housing is a reamer head having one or more fluid outlet.

The tool is characterized in that the discharge hole of the drive chamber is in fluid connection with the inlet of the subsequent drive chamber by the segment of the torsional housing to form a fluid conduit system in such a way that fluid passed from the fluid channel enters the first drive chamber and flows through the fluid conduit system connecting each subsequent drive chamber to impart rotational force on the drive chambers, the torsional housing and the stabilized housing, when the fluid is forced therethrough before exiting through the fluid outlet.

Preferably, the coupling between the drive chamber and the torsional housing further comprises a drive disc having a discharge conduit that mates with the discharge hole for fluid connection between the drive chamber and a corresponding segment of the torsional housing. Preferably, the discharge conduit is a curved conduit for creating a rotational fluid jet when the fluid exits the drive chambers. More preferably, the drive disc is in place for each drive chamber and is stacked according to the number of holes in the curved surface of the drive chamber, and locked in place with the drive chamber. The drive disc and the drive chamber act as to jet fluid against the bladed segments/impellers (310) within the internal diameter of the torsional housing.

The rotational speed, torque and power increases in positive correlation with the number of drive chambers.

Further, the dynamic sleeve comprises a bearing pack positioned radially to form a rotational connection between the dynamic sleeve and the stabilized housing.

Further, the torsional housing is segmented circumferentially and lengthwise.

Preferable, an outer wall of the stabilized housing further comprises one or more reaming extension for reaming a surface.

Preferably, the reamer head is curved or torpedo-shaped, and is attached to the stabilized housing in a rotatable connection. Alternatively, the reamer head is attached to the stabilized housing in a non-rotatable connection.

Preferably, the attachment between the reamer head and the stabilized housing is a removable attachment.

Further, the channel body further comprises a static sleeve that is functionally coupled to the dynamic sleeve. There is a static housing functionally coupled to the static sleeve, and a second sleeve in fluid connection with the static housing and functionally coupled to the static sleeve. There is a static mandrel in fluid connection with the second sleeve and functionally coupled to an interior of the static sleeve.

The fluid conduit system comprises multiple inlets, discharge holes and discharge conduits in fluid connection with multiple segments of the torsional housing in connection with two or more drive chambers.

Preferably, a last drive chamber is functionally coupled to a radial bearing and is positioned between the last drive chamber and the fluid outlet.

The present invention consists of features and a combination of parts hereinafter fully described and illustrated in the accompanying drawings, it being understood that various changes in the details may be made without departing from the scope of the invention or sacrificing any of the advantages of the present invention.

DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the embodiments of the present application are set forth in the appended claims. However, the embodiments themselves, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:

FIG. 1 illustrates a cross-sectional side view of an assembled reaming tool of the present invention.

FIG. 2 illustrates an exploded, cross-sectional side view of a reaming tool of the present invention.

FIG. 3 illustrates an exploded, side view of a reaming tool of the present invention.

FIG. 4 illustrates a cross-sectional view of section A—B of FIG. 1 .

FIG. 5 illustrates an enlarged view of drive chambers from part C of FIG. 2 .

REFERENCE NUMERALS

-   -   100—static housing     -   110—dynamic sleeve     -   111—lower bearing pack     -   120—fluid channel     -   130—static sleeve     -   140—lower static housing     -   150—threaded section of static housing to accommodate static         sleeve (130)     -   160—static mandrel     -   200—upper drive chambers     -   200′—lower drive chambers     -   200″—subsequent drive chambers     -   210—inlet     -   220—discharge hole     -   230—drive disc     -   231—discharge conduit     -   300—torsional housing/impeller sleeve     -   310 bladed segment/impeller     -   400—stabilized housing     -   410—reamer head     -   411—fluid outlet     -   420—reaming extension     -   430—radial bearing

While the system and method of use of the present application is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present application as defined by the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Illustrative embodiments of the system and method of use of the present application are provided below. It will of course be appreciated that in the development of any actual embodiment, numerous implementation-specific decisions will be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

The system and method of use will be understood, both as to its structure and operation, from the accompanying drawings, taken in conjunction with the accompanying description. Several embodiments of the system are presented herein. It should be understood that various components, parts, and features of the different embodiments may be combined together and/or interchanged with one another, all of which are within the scope of the present application, even though not all variations and particular embodiments are shown in the drawings. It should also be understood that the mixing and matching of features, elements, and/or functions between various embodiments is expressly contemplated herein so that one of ordinary skill in the art would appreciate from this disclosure that the features, elements, and/or functions of one embodiment may be incorporated into another embodiment as appropriate, unless described otherwise.

The preferred embodiment herein described is not intended to be exhaustive or to limit the invention to the precise form disclosed. It is chosen and described to explain the principles of the invention and its application and practical use to enable others skilled in the art to follow its teachings.

The general principles of the present invention relate to a tool for reaming drilled holes or tunnels using a rotational force created by forcing a fluid, such as water, through the tool. More specifically, the reaming tool is a hydraulically powered reaming tool that is structurally modified to provide increased rotational force using the same volumetric rate of fluid as compared with the previous invention.

FIGS. 1 and 2 illustrate a reaming tool in an embodiment of the present invention, with FIG. 1 showing the assembled tool while FIG. 2 showing the exploded view. The reaming tool comprises a few main parts: a channel body (100), two or more stacked drive chambers (200), torsional housing (300) and stabilized housing (400), as well as their respective components.

Channel Body (100)

The channel body (100) has a polygonal (preferably tubular) wall and is coupled to one end of the stabilized housing (400) by a dynamic sleeve (110) in such a way that the stabilized housing (400) is in rotational connection with the channel body (100) such that they are connected, but allows for rotation of the stabilized housing (400) on a rotational axis aligned with a long axis of the tool. The interior of the channel body (100), across its center, is a fluid channel (120) that allows a drilling fluid to pass through and enter the interior of the stabilized housing (400). As such, the fluid may flow from a back end of the reaming tool to exit a front end of the tool.

In a preferred embodiment (as illustrated in FIGS. 1 and 3 ), the dynamic sleeve (110) further comprises a lower bearing pack (111), such as but not limited to those of magnetic bearing systems, positioned radially to form a rotational connection at the contact area between the dynamic sleeve (110) and the stabilized housing (400). As an example, the bearing pack (111) consists of a layer of plate having one or more ball bearing, roller bearing, jewel bearing, fluid bearing, flexure bearing, composite bearing, bushing or the likes and any combination thereof. Such bearings may be made from any durable material suitable for the operation of the reaming tool, such as chrome steel, stainless steel, cast iron, carbon steel, or steel alloys of the likes. Similar bearing pack (311) maybe placed at other coupling areas.

In another preferred embodiment (as illustrated in FIGS. 2 and 3 ), the channel body (100) further comprises a static sleeve (130) that is functionally coupled to the threaded part of the lower static housing (150). The stabilized housing (400) is disposed over the static sleeve (130) of the channel body (100). There is a static housing (140), which is functionally attached to the dynamic sleeve (110) by bearings and also functionally coupled to the static sleeve (130). The static sleeve (130) is also functionally coupled to the dynamic sleeve (110) by bearings. A threaded part of the static housing (150), is in fluid connection with the upper part of the static housing (140) and is functionally coupled to the static sleeve (130). A static mandrel (160), is positioned within the static housing (150) and is functionally coupled either by friction fitting and locking pins or screws or maybe integrated into the the static sleeve (130), to an interior of the static sleeve for fluid connection between the channel body (100) and a drive chamber (200) downstream. Preferably, locking pins (111) is disposed at the coupling areas between the static sleeve (130) and the static mandrel (160).

Drive Chamber (200)

In a preferred embodiment of the present invention, two or more cylindrical (preferably tubular) drive chambers (200) are stacked one after another within the interior of the reaming tool. A first drive chamber (200′) has an open end in fluid connection with the fluid channel (120) through the static mandrel (160) and another closed end in stacking connection with one or more subsequent drive chamber (200″) having two closed ends. Each of the drive chambers (200) has one or more inlets (210) upstream for fluid entry into the drive chamber (200) and one or more discharge holes (220) at the side (curved surface) downstream for fluid discharge out of the drive chamber (200). Preferably, for subsequent drive chambers, the inlet (210) disposed at the side (curved surface) of the tubular drive chamber (200). More preferably, there are multiple inlets (210) and discharge holes (220), in even or odd numbers (one, two, four, six or more), that may be positioned in pairs at opposite sides to one another or as single holes along the length of the drive chamber but uniformly offset from each other radially around the circumference of the drive chamber (200). This configuration enables a balanced rotational force to be created when the fluid is forced to flow in and out of the drive chamber (200), through drive discs (230) to impact the torsional housing (300), as described below.

Torsional Housing (300)

Outer walls (exterior) of the drive chambers (200) are surrounded in a fixedly engagement by a torsional housing (300), also known as impeller sleeve. In a preferred embodiment, the torsional housing (300) comprises separate bladed segments (310) in the form of impellers allowing fluid flow in each segment. The torsional housing (300) is segmented circumferentially (illustrated in FIG. 4 ) and lengthwise (illustrated in FIG. 1 ). The discharge hole (220) of the drive chamber (200) is in fluid connection with the inlet (210) of the subsequent drive chamber (200″) by the segment (310) of the torsional housing (300) to form a fluid conduit system. As such, the fluid conduit system comprises multiple inlets (210) and discharge holes (230) in fluid connection with multiple segments (310) of the torsional housing (300). This fluid connection exists as high pressure jetting action against the bladed segments or impellers (310) of the torsional housing (300) as fluid exits from the drive chambers (200), through the drive discs (230). The arrangement of the drive chambers (200) and drive discs (230) are collectively called the drive mechanism. The torsional housing (300) maybe integral to the stabilized housing (400) or friction fitted inside the stabilized housing (400) in connection with two or more drive chambers (200). In a preferred embodiment of the present invention, the communication between the drive chamber (200) and the torsional housing (300) further comprises a drive disc (230) having a discharge conduit (231) that mates with the discharge hole (220) for fluid connection between the drive chamber (200) and a corresponding segment (310) of the torsional housing (300). As such, the fluid conduit system comprises multiple inlets (210), discharge holes (230) and discharge conduits (231) in fluid connection with multiple segments of the torsional housing in connection with two or more drive chambers. More preferably, the discharge conduit (231) is a curved conduit.

Stabilized Housing (400)

The stabilized housing (400) has an inner wall that is fixedly coupled around outer wall of the torsional housing (300). While back end of the stabilized housing (400) is in rotatable connection with the dynamic sleeve (110), the other end (front end) of the stabilized housing (400) is attached to a reamer head (410) having one or more fluid outlet (411) so that fluid flowing through the reaming tool may exit through the fluid outlet (411). There is a radial bearing (430) functionally coupled to the last drive chamber and positioned between the last drive chamber and the fluid outlet (411) such that the fluid from the last drive chamber is channelled towards the reamer head (410) and exits through the fluid outlet (411). The attachment between the reamer head (410) and the stabilized housing (400) is a removable attachment, such as by way of screw and thread, friction fit, male and female configuration, clip, or the likes. In a preferred embodiment of the present invention, the reamer head (410) is curved or torpedo-shaped, and is attached to the stabilized housing (400) in a rotatable connection. In an alternative embodiment, the reamer head (410) is attached to the stabilized housing (400) in a non-rotatable connection.

The outer wall (exterior) of the stabilized housing (400) further comprises a reaming extension (420) that is shaped for reaming a surface in a drilled hole that comes into contact with the rotating stabilized housing (400). In a preferred embodiment, the reaming extension (420) has a rough outer surface, such as having protrusions, for scraping or smoothening the interior of a drilled hole (illustrated in FIG. 3 ). More preferably, a similar reaming extension (420) is also disposed on the outer wall of the reamer head (410).

Operation

In operation, the back end of the reaming tool is coupled to an end of a string and dropped down a drill hole. When fluid is pumped through the string, the fluid enters the reaming tool from back end of the channel body (100). The fluid is passed from the fluid channel (120), then enters the first drive chamber (200′) and flows through the drive discs (230) and subsequently the fluid conduit system connecting each subsequent drive chamber (200″). As illustrated in FIG. 5 (arrows), the fluid does not flow directly from one end to another end of the drive chamber (200) before entering and exiting the subsequent drive chamber (200″) from one end to another end yet again. The indirect flow of the fluid which exits one drive chamber (200) before entering the inlet (220) of the subsequent drive chamber (200″) through the fluid conduit system formed with the segment/impellers (310) of the torsional housing (300) imparts a rotational force and transfers fluid energy unto torsional housing (300) and consequently the stabilized housing (400). The fluid eventually exits through the fluid outlet (411) at the reamer head (410). The rotation of the stabilized housing (400) having the reaming extension (420) results in reaming the drilled hole. The tool may be lowered/raised as desired to ream in regions of the hole where reaming may be needed due to deformations of the interior of the drilled hole.

According to a preferred embodiment as illustrated in FIG. 4 (arrows), multiple discharge conduits (231) create an array of curved conduits for creating a strong rotational or spiraling fluid jet when the fluid exits the drive chamber (200) through the drive disc (230), within the internal diameter of the torsional housing (300). This is because such a curvature forms a spiral-like shape that transforms fluid pressure/flow into angular momentum from the drive chambers unto the stabilized housing (400) as the fluid impacts the impellers (310) of the torsional housing (300). Alternatively, the curvature may be configured to form shapes like, but not limited to, line-segment spirals, elbows, discontinuous curves, straight lines with deflector structure at an end thereof, or the likes and any combination thereof. One or more drive discs (230) is in place for each drive chamber (200) and is stacked according to the stacking of the holes on the curved surface of the drive chamber (200) in such a way that the drive disc (230) is affixed together with the drive chamber (200). The drive mechanism does not rotate when fluid is displaced through the system. Besides, the rotational force (speed, torque and power) increases in positive correlation with the number of drive chambers (200) that are stacked together. For example, with the same amount of fluid that flows through the drive chambers (200), two drive chambers (200) stacked together would impart double the rotational force compared to just one drive chamber (200), three drive chambers (200) would impart triple the rotational force, and so on.

The particular embodiments disclosed above are illustrative only, as the embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. It is therefore evident that the particular embodiments disclosed above may be altered or modified, and all such variations are considered within the scope and spirit of the application. Accordingly, the protection sought herein is as set forth in the description. Although the present embodiments are shown above, they are not limited to just these embodiments, but are amenable to various changes and modifications without departing from the spirit thereof. 

What is claimed is:
 1. A reaming tool, comprising: a channel body having a tubular wall and comprising a dynamic sleeve and a fluid channel across the center of the channel body; two or more tubular, drive chambers stacked one after another, with a first drive chamber having an open end in fluid connection with the fluid channel and another closed end in stacking connection with one or more subsequent drive chamber having two closed ends, wherein outer walls of the drive chambers are surrounded in a fixedly engagement by a torsional housing having separate segments allowing fluid flow in each segment, each drive chamber having one or more inlet upstream for fluid entry and one or more discharge hole downstream for fluid discharge; and a stabilized housing having an inner wall fixedly coupled around the torsional housing and one end of the stabilized housing rotatably coupled with the dynamic sleeve of the channel body, and another end of the stabilized housing is a reamer head having one or more fluid outlet, characterized in that the discharge hole of the drive chamber is in fluid connection with the inlet of the subsequent drive chamber by the segment of the torsional housing to form a fluid conduit system in such a way that a fluid passed from the fluid channel enters the first drive chamber and flows through the fluid conduit system connecting each subsequent drive chamber to impart rotational force on the torsional housing and the stabilized housing, when the fluid is forced therethrough before exiting through the fluid outlet.
 2. The reaming tool according to claim 1, wherein the communication between the drive chamber and the torsional housing further comprising a drive disc having a discharge conduit that mates with the discharge hole for fluid connection between the drive chamber and a corresponding segment of the torsional housing.
 3. The reaming tool according to claim 2, wherein the discharge conduit is a curved conduit for creating a rotational fluid jet when the fluid exists the drive chamber.
 4. The reaming tool according to claim 2, wherein the drive disc is in place for each drive chamber and is stacked according to the number of holes in the curved surface of the drive chamber.
 5. The reaming tool according to claim 2, wherein the drive disc and the drive chamber act as to jet fluid against the bladed segments/impellers within the internal diameter of the torsional housing.
 6. The reaming tool according to claim 1, wherein the rotational force increases in positive correlation with the number of drive chamber.
 7. The reaming tool according to claim 1, wherein the dynamic sleeve further comprising a bearing pack positioned radially to form a rotational connection between the dynamic sleeve and the stabilized housing.
 8. The reaming tool according to claim 1, wherein the torsional housing is segmented circumferentially and lengthwise.
 9. The reaming tool according to claim 1, wherein an outer wall of the stabilized housing further comprising one or more reaming extension for reaming a surface.
 10. The reaming tool according to claim 1, wherein the reamer head is curved or torpedo-shaped.
 11. The reaming tool according to claim 1, wherein the reamer head is attached to the stabilized housing (400) in a rotatable connection.
 12. The reaming tool according to claim 1, wherein the reamer head is attached to the stabilized housing in a non-rotatable connection.
 13. The reaming tool according to claim 11, wherein the attachment between the reamer head and the stabilized housing is a removable attachment.
 14. The reaming tool according to claim 12, wherein the attachment between the reamer head and the stabilized housing is a removable attachment.
 15. The reaming tool according to claim 1, wherein the channel body further comprising: a static sleeve functionally coupled to the dynamic sleeve; a static housing functionally coupled to the static sleeve; a second sleeve functionally coupled to the static sleeve; and a static mandrel functionally coupled to an interior of the static sleeve.
 16. The reaming tool according to claim 1, wherein the fluid conduit system comprising multiple inlets, discharge holes and discharge conduits in fluid connection with multiple segments of the torsional housing in connection with two or more drive chambers.
 17. The reaming tool according to claim 1, wherein a last drive chamber is functionally coupled to a radial bearing and is positioned between the last drive chamber and the fluid outlet. 